CN105690688A - 一种双轴或三轴偏心转子体积脉动形变塑化加工方法及设备 - Google Patents

一种双轴或三轴偏心转子体积脉动形变塑化加工方法及设备 Download PDF

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CN105690688A
CN105690688A CN201610150876.3A CN201610150876A CN105690688A CN 105690688 A CN105690688 A CN 105690688A CN 201610150876 A CN201610150876 A CN 201610150876A CN 105690688 A CN105690688 A CN 105690688A
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Prior art keywords
eccentric
rotor
eccentric rotor
stator
helical structure
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CN201610150876.3A
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瞿金平
杨智韬
冯彦洪
殷小春
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South China University of Technology SCUT
Guangzhou Huaxinke Industrial Co Ltd
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South China University of Technology SCUT
Guangzhou Huaxinke Industrial Co Ltd
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Application filed by South China University of Technology SCUT, Guangzhou Huaxinke Industrial Co Ltd filed Critical South China University of Technology SCUT
Priority to CN201610150876.3A priority Critical patent/CN105690688A/zh
Publication of CN105690688A publication Critical patent/CN105690688A/zh
Priority to RU2018106683A priority patent/RU2709864C1/ru
Priority to MX2018002603A priority patent/MX2018002603A/es
Priority to SG11201710024XA priority patent/SG11201710024XA/en
Priority to KR1020187003657A priority patent/KR20180116208A/ko
Priority to JP2018504875A priority patent/JP6657372B2/ja
Priority to PCT/CN2016/109613 priority patent/WO2017157061A1/zh
Priority to BR112017028422-7A priority patent/BR112017028422A2/pt
Priority to AU2016397261A priority patent/AU2016397261B2/en
Priority to EP16894220.9A priority patent/EP3299141B1/en
Priority to CA2989360A priority patent/CA2989360C/en
Priority to US15/743,795 priority patent/US10632656B2/en
Priority to HK18110176.5A priority patent/HK1250691A1/zh
Pending legal-status Critical Current

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Abstract

本发明公开了一种双轴或三轴偏心转子体积脉动形变塑化加工方法及设备。该方法由螺旋结构和偏心圆柱结构交替连接组成的两根或三根啮合的偏心转子与定子内表面形成的物料输运体积分别沿转子轴向和径向周期性的变化,物料在两根或三根啮合的偏心转子啮合转动过程中实现基于脉动体积形变熔融塑化输运。该设备偏心转子均由长度变化的螺旋结构和偏心圆柱结构交替连接组成;偏心转子的螺旋结构结构相互啮合,两根或三根转子偏心圆柱结构所处轴向位置均相同。本发明可实现高分子材料的挤出加工或与柱塞注射单元组合实现高分子材料的注塑加工,具有物料混炼塑化效果好、热机械历程短、能耗低、适应性广等特点。

Description

一种双轴或三轴偏心转子体积脉动形变塑化加工方法及设备
技术领域
本发明涉及高分子材料塑化加工方法与设备,特别是涉及一种高分子材料双轴、三轴偏心转子体积脉动形变塑化加工方法及设备。
技术背景
双、三螺杆挤出加工是高分子材料加工过程中的一种重要方法,相对于单螺杆挤出加工,双、三螺杆挤出加工具有更好的混合混炼、反应和排气效果,适合于加工热稳定性差的塑料,特别适合于加工共混料。双、三螺杆挤出加工物料的塑化输送过程主要依赖于螺杆旋转时对物料的剪切拖曳作用,因此当前双、三螺杆加工高分子材料普遍存在热机械历程长、加工能耗高、混合混炼效果差、设备结构庞大以及对物料依赖性强等缺陷。为了提高高分子材料的混合、混炼效果,降低高分子材料在塑化输运过程中的能耗,一些研究者在螺杆的某些部位增设捏合元件使塑化加工过程中的局部流场受拉伸流变控制,但是这种局部流场的控制并未改变物料在双、三螺杆挤出加工塑化输运过程中受剪切流变支配的机理。
随着当前新型高分子材料如植物纤维增强材料、可降解材料、高性能材料等层出不穷,同时对于高分子材料制品的尺寸精度、混合分散特性、力学性能等各项指标的要求也越来越高,因此对于高分子材料的塑化加工设备也提出了更高的要求。基于拉伸流变的叶片聚合物塑化输运方法是通过物料加工体积周期性变化强制物料熔融塑化和混合混炼,物料的流动和变形主要受拉伸应力支配,主速度梯度与其主流动和变形的方向一致,表现出拉伸流变行为,从而解决了螺杆加工机械塑化能力主要依赖物料外摩擦力和内摩擦力的问题。与螺杆塑化输运方法相比,叶片塑化输运方法具有能耗低、热机械历程短、对物料适应性高、分散混合效果好等优点;但是在叶片塑化输运过程中,聚合物输送通道非流线型,不利于加工热敏型聚合物的塑化与混合改性。
针对目前高分子材料加工行业所存在的问题,开发一种能够显著提高高分子材料的分散混合、塑化混炼效果,缩短热机械历程并降低能耗,有效避免高分子材料在加工过程热降解的塑化输运新方法和新设备对于高分子材料加工成型领域具有重要意义。
发明内容
本发明的目的在于提供一种双、三轴偏心转子体积脉动形变塑化输运加工方法,以解决高分子材料成型加工过程中物料经历的热机械历程长、物料混炼塑化不均、混合分散性差、能耗高等问题。
本发明的目的还在于提供一种实现双、三轴偏心转子体积脉动形变塑化加工方法的设备。
本发明目的通过如下技术方案实施:
一种双轴或三轴偏心转子体积脉动形变塑化加工方法:由螺旋结构和偏心圆柱结构交替连接组成的两根或三根啮合的偏心转子与定子内表面形成的物料输运体积分别沿转子轴向和径向周期性的变化,物料在两根或三根啮合的偏心转子啮合转动过程中实现基于脉动体积形变熔融塑化输运。
一种实现上述方法的双轴或三轴偏心转子体积脉动形变塑化加工设备:主要由料斗、两根或三根偏心转子、定子和驱动装置组成,偏心转子排列置于定子内腔中,偏心转子分别与驱动装置连接;料斗和定子内腔连通,偏心转子均由长度变化的螺旋结构和偏心圆柱结构交替连接组成;偏心转子的螺旋结构结构相互啮合,两根或三根转子偏心圆柱结构所处轴向位置均相同。
为进一步实现本发明目的,优选地,两根或三根转子的螺旋部分轴线与转子旋转轴线相同,偏心圆柱轴线与转子旋转轴线偏心,且同根转子上的不同位置的偏心圆柱偏心方向相同。
优选地,所述偏心转子的螺旋结构的螺距和偏心圆柱的长度均沿轴向逐渐减小。
优选地,所述偏心转子为三根,分别是中间偏心转子、右侧偏心转子和左侧偏心转子;中间偏心转子、右侧偏心转子和左侧偏心转子呈“一”字水平排列置于定子的内腔中;中间偏心转子的螺旋结构与右侧偏心转子和左侧偏心转子螺旋结构相互啮合。
优选地,所述偏心转子为两根,分别是第一偏心转子和第二偏心转子,第一偏心转子和第二偏心转子同向或者异向啮合置于定子的内腔中。
优选地,所述设备主要由三轴偏心转子体积脉动形变塑化输运单元和柱塞注射单元构成,所述三轴偏心转子体积脉动形变塑化输运单元主要由料斗、中间偏心转子、右侧偏心转子、左侧偏心转子、定子和驱动装置组成;柱塞注射单元主要由连接件、柱塞和缸体组成;缸体通过连接件与定子连接,柱塞和缸体连接;中间偏心转子、右侧偏心转子和左侧偏心转子均置于定子内腔中,分别与驱动装置连接;螺旋结构的螺距和偏心圆柱的长度均沿轴向逐渐减小;中间偏心转子的螺旋结构与右侧偏心转子和左侧偏心转子的螺旋结构相互啮合。
本发明可实现高分子材料的挤出加工或与柱塞注射单元组合实现高分子材料的注塑加工。
相对于现有技术,本发明解决高分子材料成型加工过程中物料经历的热机械历程长、物料混炼塑化不均、混合分散性差、能耗高等问题,与传统高分子材料加工技术及设备相比,具有以下优点:
1、物料在特定空间中体积发生周期性变化而完成塑化输运过程,这种过程是基于脉动体积形变支配作用下进行的,相对于传统的基于剪切流变支配的螺杆塑化输运过程,其所经历的热机械历程大大缩短,塑化输运能耗降低;
2、具有特殊表面结构的两根或三根啮合转子与定子内表面形成的物料输运体积分别沿转子轴向和径向呈周期性的变化,强化了高分子材料塑化混炼、混合分散效果,对物料适应性提高;
3、物料塑化输运过程连续,具有完全正位移特性,挤出稳定性和效率都大大提高;
4、装置拆装方便,便于应用和推广。
附图说明
图1为实施例1双轴同向啮合偏心转子体积脉动形变塑化加工设备的结构示意图;
图2为图1的A-A向剖视图;
图3为实施例2双轴异向啮合偏心转子体积脉动形变塑化加工设备的结构示意图;
图4为图3的B-B向剖视图;
图5为实施例3三轴偏心转子体积脉动形变塑化注射加工设备的结构示意图。
图6为图5的C-C剖视图;
图7为实施例4三轴偏心转子体积脉动形变塑化注射加工设备的结构示意图。
具体实施方式
下面结合附图和实施例对本发明做进一步的说明,但本发明要求保护的范围并不局限于实施例表述的范围。
实施例1
如图1、图2所示,同向旋转双轴偏心转子体积脉动形变塑化加工设备主要由料斗1、第一偏心转子2、第二偏心转子3、定子6和驱动装置组成,其中,第一偏心转子2和第二偏心转子3相互啮合置于定子6内腔中,分别与驱动装置连接,料斗1和定子内腔连通,第一偏心转子2和第二偏心转子3同向旋转;第一偏心转子2和第二偏心转子3均由螺旋结构4和长度变化的偏心圆柱结构5交替连接组成,螺旋结构4的螺距和偏心圆柱5的长度均沿轴向逐渐减小;第一偏心转子2的螺旋结构4与第二偏心转子3的螺旋结构4相互啮合,第一偏心转子2和第二偏心转子3的偏心圆柱结构5所处轴向位置相同。第一偏心转子2和第二偏心转子3的螺旋部分4轴线与转子旋转轴线相同,偏心圆柱5轴线与转子旋转轴线偏心,且同根转子上的不同位置的偏心圆柱偏心方向相同。第一偏心转子2和第二偏心转子3同向旋转时,两转子偏心圆柱5外表面与定子6内表面以及螺旋结构4螺棱顶部形成容腔,容腔体积随偏心圆柱5滚动沿第一偏心转子2和第二偏心转子3轴向和径向周期性变化,当容腔体积由小变大时纳入物料,体积由大变小时,物料在正应力以及定子6外加热的作用下被研磨、压实、排气和塑化熔融,最后从模头排出。
实施例2
如图3、图4所示,异向旋转双轴偏心转子体积脉动形变塑化加工设备主要由料斗1、第一偏心转子2、第二偏心转子3、定子6和驱动装置组成,其中,第一偏心转子2和第二偏心转子3相互啮合置于定子6的内腔中,分别与驱动装置连接,料斗1和定子内腔连通;第一偏心转子2和第二偏心转子3均由螺旋结构4和长度变化的偏心圆柱结构5交替连接组成,螺旋结构4的螺距和偏心圆柱5的长度均沿轴向逐渐减小;第一偏心转子2的螺旋结构4与第二偏心转子3的螺旋结构4相互啮合,第一偏心转子2和第二偏心转子3的偏心圆柱结构5所处轴向位置相同。第一偏心转子2和第二偏心转子3的螺旋部分4轴线与转子旋转轴线相同,偏心圆柱5轴线与转子旋转轴线偏心,且同根转子上的不同位置的偏心圆柱偏心方向相同。第一偏心转子2和第二偏心转子3异向旋转时,两转子偏心圆柱5外表面与定子6内表面以及螺旋结构4螺棱顶部形成容腔,容腔体积随偏心圆柱5滚动沿第一偏心转子2和第二偏心转子3轴向和径向周期性变化,当容腔体积由小变大时纳入物料,体积由大变小时,物料在正应力以及定子6外加热的作用下被研磨、压实、排气和塑化熔融,最后从模头排出。
实施例3
如图5、图6所示,三轴偏心转子体积脉动形变塑化加工设备主要由料斗1、三根转子(中间偏心转子3、右侧偏心转子2和左侧偏心转子4)、定子7和驱动装置组成,其中,中间偏心转子3、右侧偏心转子2和左侧偏心转子4呈“一”字水平排列置于定子7内腔中,分别与驱动装置连接,料斗1和定子内腔连通;中间偏心转子3、右侧偏心转子2和左侧偏心转子4均由螺旋结构5和长度变化的偏心圆柱结构6交替连接组成,螺旋结构5的螺距和偏心圆柱6的长度均沿轴向逐渐减小;中间偏心转子3的螺旋结构5与右侧偏心转子2和左侧偏心转子4螺旋结构5相互啮合,中间偏心转子3、右侧偏心转子2和左侧偏心转子4的偏心圆柱结构6所处轴向位置均相同。中间偏心转子3、右侧偏心转子2和左侧偏心转子4的螺旋部分5轴线与转子旋转轴线相同,偏心圆柱6轴线与转子旋转轴线偏心,且同根转子上的不同位置的偏心圆柱偏心方向相同。中间偏心转子3、右侧偏心转子2和左侧偏心转子4旋转时,三转子偏心圆柱6外表面与定子7内表面以及螺旋结构5螺棱顶部形成容腔,容腔体积随偏心圆柱6滚动沿中间偏心转子3、右侧偏心转子2和左侧偏心转子4轴向和径向周期性变化,当容腔体积由小变大时纳入物料,体积由大变小时,物料在正应力以及定子7外加热的作用下被研磨、压实、排气和塑化熔融,最后从模头排出。
实施例4
如图7所示,三轴偏心转子体积脉动形变塑化注射加工设备主要由三轴偏心转子体积脉动形变塑化输运单元和柱塞注射单元构成,其中,三轴偏心转子体积脉动形变塑化输运单元主要由料斗1、三根转子(中间偏心转子3、右侧偏心转子2和左侧偏心转子4)、定子7和驱动装置组成,柱塞注射单元主要由连接件8、柱塞9和缸体10组成。缸体10通过连接件8与定子7连接,柱塞9和缸体10连接;中间偏心转子3、右侧偏心转子2和左侧偏心转子4均置于定子7内腔中,分别与驱动装置连接,料斗1和定子内腔连通;中间偏心转子3、右侧偏心转子2和左侧偏心转子4均由螺旋结构5和长度变化的偏心圆柱结构6交替连接组成,螺旋结构5的螺距和偏心圆柱6的长度均沿轴向逐渐减小;中间偏心转子3的螺旋结构5与右侧偏心转子2和左侧偏心转子4的螺旋结构5相互啮合,中间偏心转子3、右侧偏心转子2和左侧偏心转子4的偏心圆柱结构6所处轴向位置均相同;中间偏心转子3、右侧偏心转子2和左侧偏心转子4旋转时,三转子偏心圆柱6外表面与定子7内表面以及螺旋结构5螺棱顶部形成容腔,容腔体积随偏心圆柱6滚动沿中间偏心转子3、右侧偏心转子2和左侧偏心转子4轴向和径向周期性变化,将物料塑化熔融,并通过连接件8输运进入缸体10中,同时柱塞9不断后退。当缸体10中的物料熔体储料量达到注射制品要求的计量值时,三轴偏心转子体积脉动形变塑化输运单元停止塑化熔融,注射机的塑化计量工序结束。待注射机完成充模、保压工序后,在制品冷却阶段三轴偏心转子体积脉动形变塑化输运单元开始塑化输运,注射机开始制品成型的新一个周期。
本发明物料在特定空间中体积发生周期性变化而完成塑化输运过程,这种过程是基于脉动体积形变支配作用下进行的,相对于传统的基于剪切流变支配的螺杆塑化输运过程,其所经历的热机械历程大大缩短,塑化输运能耗降低;
本发明具有特殊表面结构的两根或三根啮合转子与定子内表面形成的物料输运体积分别沿转子轴向和径向呈周期性的变化,强化了高分子材料塑化混炼、混合分散效果,对物料适应性提高;物料塑化输运过程连续,具有完全正位移特性,挤出稳定性和效率都大大提高;本发明设备拆装方便,便于应用和推广。
本发明可实现高分子材料的挤出加工或与柱塞注射单元组合实现高分子材料的注塑加工,具有物料混炼塑化效果好、热机械历程短、能耗低、适应性广等特点。

Claims (7)

1.一种双轴或三轴偏心转子体积脉动形变塑化加工方法,其特征在于:由螺旋结构和偏心圆柱结构交替连接组成的两根或三根啮合的偏心转子与定子内表面形成的物料输运体积分别沿转子轴向和径向周期性的变化,物料在两根或三根啮合的偏心转子啮合转动过程中实现基于脉动体积形变熔融塑化输运。
2.一种实现权利要求1所述方法的双轴或三轴偏心转子体积脉动形变塑化加工设备,其特征在于:主要由料斗、两根或三根偏心转子、定子和驱动装置组成,偏心转子排列置于定子内腔中,偏心转子分别与驱动装置连接;料斗和定子内腔连通,偏心转子均由长度变化的螺旋结构和偏心圆柱结构交替连接组成;偏心转子的螺旋结构结构相互啮合,两根或三根转子偏心圆柱结构所处轴向位置均相同。
3.根据权利要求2所述的设备,其特征还在于:两根或三根转子的螺旋部分轴线与转子旋转轴线相同,偏心圆柱轴线与转子旋转轴线偏心,且同根转子上的不同位置的偏心圆柱偏心方向相同。
4.根据权利要求2所述的设备,其特征在于:所述偏心转子的螺旋结构的螺距和偏心圆柱的长度均沿轴向逐渐减小。
5.根据权利要求2-4任一项所述的设备,其特征在于:所述偏心转子为三根,分别是中间偏心转子、右侧偏心转子和左侧偏心转子;中间偏心转子、右侧偏心转子和左侧偏心转子呈“一”字水平排列置于定子的内腔中;中间偏心转子的螺旋结构与右侧偏心转子和左侧偏心转子螺旋结构相互啮合。
6.根据权利要求2-4任一项所述的设备,其特征在于:所述偏心转子为两根,分别是第一偏心转子和第二偏心转子,第一偏心转子和第二偏心转子同向或者异向啮合置于定子的内腔中。
7.根据权利要求2所述的设备,其特征在于:所述设备主要由三轴偏心转子体积脉动形变塑化输运单元和柱塞注射单元构成,所述三轴偏心转子体积脉动形变塑化输运单元主要由料斗、中间偏心转子、右侧偏心转子、左侧偏心转子、定子和驱动装置组成;柱塞注射单元主要由连接件、柱塞和缸体组成;缸体通过连接件与定子连接,柱塞和缸体连接;中间偏心转子、右侧偏心转子和左侧偏心转子均置于定子内腔中,分别与驱动装置连接;螺旋结构的螺距和偏心圆柱的长度均沿轴向逐渐减小;中间偏心转子的螺旋结构与右侧偏心转子和左侧偏心转子的螺旋结构相互啮合。
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